EP3244692B1 - Elektrisch beheizbarer schichtstapel - Google Patents

Elektrisch beheizbarer schichtstapel Download PDF

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Publication number
EP3244692B1
EP3244692B1 EP16168951.8A EP16168951A EP3244692B1 EP 3244692 B1 EP3244692 B1 EP 3244692B1 EP 16168951 A EP16168951 A EP 16168951A EP 3244692 B1 EP3244692 B1 EP 3244692B1
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EP
European Patent Office
Prior art keywords
layer
cnt
layer stack
substrate
electrically heatable
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EP16168951.8A
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English (en)
French (fr)
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EP3244692A1 (de
Inventor
Peter Linde
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Airbus Operations GmbH
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Airbus Operations GmbH
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Priority to EP16168951.8A priority Critical patent/EP3244692B1/de
Priority to US15/482,178 priority patent/US11122649B2/en
Publication of EP3244692A1 publication Critical patent/EP3244692A1/de
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    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/10—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor
    • H05B3/12—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material
    • H05B3/14—Heater elements characterised by the composition or nature of the materials or by the arrangement of the conductor characterised by the composition or nature of the conductive material the material being non-metallic
    • H05B3/145—Carbon only, e.g. carbon black, graphite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/0036—Heat treatment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B64—AIRCRAFT; AVIATION; COSMONAUTICS
    • B64D—EQUIPMENT FOR FITTING IN OR TO AIRCRAFT; FLIGHT SUITS; PARACHUTES; ARRANGEMENTS OR MOUNTING OF POWER PLANTS OR PROPULSION TRANSMISSIONS IN AIRCRAFT
    • B64D15/00—De-icing or preventing icing on exterior surfaces of aircraft
    • B64D15/12—De-icing or preventing icing on exterior surfaces of aircraft by electric heating
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B1/00—Details of electric heating devices
    • H05B1/02—Automatic switching arrangements specially adapted to apparatus ; Control of heating devices
    • H05B1/0227—Applications
    • H05B1/023—Industrial applications
    • H05B1/0236—Industrial applications for vehicles
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B3/00—Ohmic-resistance heating
    • H05B3/20—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater
    • H05B3/22—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible
    • H05B3/26—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base
    • H05B3/267—Heating elements having extended surface area substantially in a two-dimensional plane, e.g. plate-heater non-flexible heating conductor mounted on insulating base the insulating base being an organic material, e.g. plastic
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B6/00—Heating by electric, magnetic or electromagnetic fields
    • H05B6/46—Dielectric heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/42—Alternating layers, e.g. ABAB(C), AABBAABB(C)
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/20—Inorganic coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/20—Properties of the layers or laminate having particular electrical or magnetic properties, e.g. piezoelectric
    • B32B2307/206—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/18—Aircraft
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B2214/00—Aspects relating to resistive heating, induction heating and heating using microwaves, covered by groups H05B3/00, H05B6/00
    • H05B2214/04—Heating means manufactured by using nanotechnology

Definitions

  • the present disclosure generally relates to heating elements.
  • the disclosure relates in particular to an electrically heatable layer stack. It further relates to a vehicle assembly group, an aircraft, a method and a system for manufacturing an electrically heatable layer stack.
  • temperatures at an outside of the aircraft are often as low as minus 50 degrees Celsius. Without any countermeasures being taken, such temperatures may rapidly cause icing especially of those parts of the aircraft which are most exposed to the stream of ambient air, for example, the leading edges of the wings. However, ice build-up on the wing surfaces would undesirably influence the aerodynamical properties of the wing.
  • movable parts such as slats, which are used for steering the aircraft, are accommodated in the front portion of the wings. Icing in these areas could thus easily block the parts and inhibit proper functioning.
  • Such techniques typically involve heating in some way the relevant areas to thereby prevent the forming of ice (so-called 'anti-icing') or remove existing aggregations of ice ('de-icing') by melting.
  • a known method of heating the leading edge of an aircraft wing is to guide hot air from an engine of the aircraft to the target areas. Bleeder air is guided through air pipes inside the wing and directed against an inside surface of the wing skin.
  • controlling and adjusting the temperature of the bleeder air as needed at the target areas is often difficult.
  • tapping bleeder air from the engine decreases the efficiency of the engine.
  • the technique requires installation of air piping, nozzles and other devices inside the wings, which increases the weight of the aircraft.
  • heating of the skin is caused by convection and at the inside of the skin whereas de-icing is required at the outside. Sufficient heat must therefore permeate the entire thickness of the wing skin. All this renders the technique little energy efficient.
  • An alternative method involves electric heating mats, which are attached along the inside of the wing skin. Compared to the use of bleeder air, this technique requires less weighty installations and allows for an easier control of the temperature. However, such heating mats still cause significant extra weight and require cumbersome inspection. Moreover, due to their installation at the inside of the skin, they too have the drawback of low energy efficiency for heating an outside of the skin.
  • WO 2008/085550 A2 discloses an electrically heatable layer stack for a wing skin according to the preamble of claim 1.
  • an electrically heatable layer stack comprises at least two substrate layers, and at least one carbon nanotubes-, CNT-, layer, which is arranged between the substrate layers and which is configured to conduct an electric current.
  • the substrate layers and the at least one CNT-layer are configured to produce heating of at least one of the substrate layers when an electric current is applied to the at least one CNT-layer.
  • the substrate layers and the CNT-layer may be configured to produce the heating at least essentially by way of remote Joule heating.
  • the remote Joule heating may be caused in the substrate layer.
  • An amount of remote Joule heating in the substrate layer may exceed an amount of Joule heating in the CNT-layer, for example by a factor of 2 or more.
  • the CNT-layer may be configured to conduct the electric current in a plane of the CNT-layer.
  • the CNT-layer may be configured to conduct the electric current from a first side surface of the layer stack to a second side surface of the layer stack.
  • the first and the second side surfaces may be opposite side surfaces of the layer stack.
  • the plane of the CNT-layer may be parallel to a surface plane of each of the substrate layers which is adjacent to the CNT-layer.
  • the CNT-layer may comprise a mesh of mutually crossing carbon nanotubes, CNTs, which extends in the plane of the CNT-layer.
  • the CNTs may be distributed over the plane of the CNT-layer and/or the CNTs may be randomly oriented.
  • an areal and/or a spatial density of the distributed CNTs and a length of the CNTs may be such that on average at least one contact exists between each CNT and at least one of its neighbouring CNTs.
  • At least some of the CNTs may be entangled CNTs.
  • An average mesh size may be such that a resultant pattern of remote Joule heating in the substrate layer in combination with heat conduction in the substrate layer causes an at least essentially even temperature over a plane through the substrate layer.
  • the layer stack may further comprise at least one electrode configured for applying an electric current to the CNT-layer.
  • the electrode may be formed at least essentially over the width of a side surface of the layer stack.
  • the electrode may comprise an electroconductive film which is embedded at least partly in the layer stack.
  • the layer stack may comprise two electrodes which electrically contact the CNT-layer. The two electrodes may contact the CNT-layer at least essentially at opposite side surfaces of the layer stack.
  • the elctrodes may be configured to become electrically connected to opposite poles of a current source.
  • the layer stack may further comprise a heat sensor.
  • the heat sensor may be part of a control system for controlling a current that is applied to the electrodes of the layer stack.
  • the substrate layers may comprise electrically insulating material.
  • a substrate layer having a surface adjacent to the CNT-layer may be configured to electrically insulate the CNT-layer from an opposite surface of the substrate layer.
  • the substrate layers may comprise polymer resin.
  • the polymer resin may be a thermoplastic resin.
  • the polymer resin may be a thermoset resin.
  • each substrate may at least essentially consist of thermoplastic resin.
  • a thickness of the substrate layers lies within a range of 0.05 mm to 0.5 mm.
  • a thickness of the substrate layers may lie within a range of 0.1 mm to 0.4 mm.
  • the layer stack may comprise a plurality of substrate layers and a plurality of CNT-layers. At least some of the substrate layers and some of the CNT-layers may be arranged alternately in the layer stack.
  • the substrate layers may electrically insulate the CNT-layers from one another. Some of the substrate layers in the layer stack may not alternate with CNT-layers.
  • the layer stack may have a height in the range of 1 mm to 20 mm.
  • the layer stack may have a height in the range of 2 mm to 10 mm.
  • a height of the layer stack may not be constant.
  • a height of the layer stack may vary between 2 mm and 10 mm.
  • a thickness of each layer may at least essentially be constant, whereas a number of layers in the layer stack may vary between different sections of the layer stack.
  • a number of layers in the layer stack may vary gradually between different sections of the layer stack.
  • a vehicle assembly group comprises a layer stack as presently described.
  • the vehicle assembly group may comprise at least parts of a skin of the vehicle.
  • the layer stack may form an outside surface of the skin of the vehicle and/or be arranged close to an outside surface of the skin of the vehicle.
  • the vehicle assembly group may be an aircraft assembly group. Also, the vehicle assembly group may comprise at least parts of a wing of an aircraft.
  • the layer stack may be arranged at least partly in a region corresponding to a leading edge of the wing of the aircraft. The layer stack may extend at least essentially over a length of the wing.
  • the vehicle assembly group may comprise at least parts of a fuselage and/or a tail fin of an aircraft.
  • an aircraft comprising a vehicle assembly group as presently described.
  • the aircraft comprises at least two vehicle assembly groups each of which comprises at least parts of a different wing of the aircraft.
  • a method for manufacturing an electrically heatable layer stack comprises providing a first substrate layer and spraying, onto the first substrate layer, a dispersion comprising a dispersing agent and carbon nanotubes, CNTs, in dispersed state.
  • the method further comprises removing the dispersing agent from the sprayed-on dispersion such that a CNT-layer configured to conduct an electric current is formed on the substrate layer.
  • the method further comprises providing a second substrate layer, and laminating the second substrate layer onto the CNT-layer.
  • the method may further comprise, subsequent to providing the first substrate layer, laminating the first substrate layer onto a base structure. Additionally, spraying the dispersion may be performed at least partly in synchrony with laminating the first substrate layer. In addition or as an alternative, the method may be performed repeatedly, for example, in an iterating manner, to produce a layer stack having a plurality of CNT-layers and a plurality of substrate layers which are arranged alternately in the layer stack. The dispersing agent may be removed at least partly by evaporation of the dispersing agent.
  • the base structure may be shaped in accordance with an intended shape of the layer stack.
  • a system for manufacturing an electrically heatable layer stack as presently described comprises a substrate lamination head configured for laminating a substrate onto a base structure to thereby form a substrate layer of the layer stack.
  • the system further comprises a spraying device configured for spraying, onto the substrate layer, a dispersion comprising a dispersing agent and carbon nanotubes, CNTs, in dispersed state, so as to form, on the substrate layer, a CNT-layer configured to conduct an electric current.
  • the substrate lamination head and the spraying device are further configured to facilitate spraying the dispersion at least partly in synchrony with laminating the substrate layer.
  • the system may further comprise regulating means for regulating a feeding of the dispersion to the spraying device.
  • Figure 1 shows an electrically heatable layer stack 100 according to an embodiment.
  • the layer stack 100 comprises two substrate layers 110a, 110b and a carbon nanotubes-, CNT-, layer 120 arranged between the substrate layers 110a, 110b.
  • the substrate layers 110a, 110b are made of electrically insulating material.
  • the substrate layers 110a, 110b comprise thermoplastic or thermoset polymer resin.
  • the substrate layers 110a, 110b may also comprise other types of electrically insulating material.
  • the substrate layers 110a, 110b have a thickness between 0.05 mm and 0.5 mm.
  • the CNT layer 120 comprises carbon nanotubes, CNTs, distributed over a plane of the CNT layer 120.
  • the CNT layer 120 is further configured to conduct an electric current which may be applied to the CNT layer 120.
  • the CNT layer 120 is configured to conduct an electric current which is applied at one side surface of the layer stack 100 towards another side surface, for example an opposite side surface, of the layer stack 100.
  • the CNT layer 120 is configured to conduct the electric current such that the electric current flows, at least essentially, over an entire planar extension of the CNT layer 120.
  • the CNT layer 120 comprises a mesh of CNTs extending substantially in the plane of the CNT layer 120.
  • the mesh of CNTs is produced by statistically distributing the CNTs over the top surface of the lower substrate layer 110b, wherein each CNT adopts a partly random orientation in the plane of the CNT layer 120.
  • an areal or spatial density of the distributed CNTs is chosen with regard to an average length of each CNT such that a statistical redundancy in physical contacts between adjacent CNTs is achieved.
  • the creation of the redundant mesh is facilitated by the use of so-called 'entangled' CNTs.
  • entangled CNTs multiple CNTs have been connected to one another to thereby form a longer structure. Such longer structures increase the likelihood of intersection between neighboring CNTs and facilitate the forming of a regular mesh in the plane of the CNT layer 120.
  • the layers 110a, 110b, 120 of the layer stack 100 are configured to produce heating in at least one of the substrate layers 110a, 110b, when an electric current is applied to the CNT layer 120.
  • the heating results mainly from remote Joule heating inside the insulating material of the substrate layers 110, 110b when a current flows through the adjacent CNT layer 120.
  • the effect of remote Joule heating in connection with carbon nanotubes has been known for some time.
  • remote Joule heating is caused in silicone comprising substrates when a current flows through a carbon nanotube in the vicinity of a substrate.
  • remote Joule heating does not cause an immediate heating of the electric conductor through which the current is flowing. Instead, remote Joule heating occurs in material, especially electrically insulating material, in the vicinity of the electric conductor. At the same time, the effect of remote Joule heating typically exceeds by far that of conventional heating in the electric conductor.
  • applying an electric current to the CNT layer 120 and the resulting current flow at least over essential parts of the plane of the CNT layer 120 will produce a pattern of heated areas in the adjacent substrate layers 110a, 110b corresponding to the mesh of CNTs through which the electric current is flowing.
  • an even rise in temperature in a plane of each of the substrate layers 110a, 110b can be achieved.
  • the upper and the lower surface of the layer stack 100 can become evenly heated.
  • Figure 2 shows another embodiment of an electrically heatable layer stack 200. Similar to the layer stack 100 shown in figure 1 , the layer stack 200 of figure 2 comprises a sub-stack of two substrate layers 210a, 210b with a CNT layer 220a sandwiched in between. Different from figure 1 , however, the layer stack 200 comprises a plurality of CNT layers 220a, 220b, 220c, each of which is sandwiched between two substrate layers 210a to 210d, respectively. Meanwhile, for each sub-stack of a CNT layer and two adjacent substrate layers, the details set forth above in connection with figure 1 apply correspondingly. However, compared to the layer stack 100 of figure 1 , due to the provision of multiple functional sub-stacks, the layer stack 200 of figure 2 is suited to produce higher temperatures, more effective heating and/or better control over the heating process.
  • the layer stack 200 further comprises electrodes 230a-230c, 232a-232c, each of which is connected to one of the CNT layers 220a to 220c.
  • the electrodes 230a-230c, 232a-232c are shown partly embedded in the layer stack 200.
  • Each electrode 230a-230c, 232a-232c is further connected to one of opposite poles of an electric current source 240.
  • the electrodes 230a-230c, 232a-232c are arranged at opposite side surfaces of the layer stack 200 and connected to the current source 240 such that parallel electric circuits are produced. Moreover, in the shown example, electrodes which are connected to the same pole of the current source 240 are arranged at the same side surface of the layer stack 200, respectively, thus causing identical flow directions of the electric current in each of the CNT layers 220a-220c. In other examples, however, other arrangements are chosen, in which flow directions of the electric current in neighboring CNT layers 220a to 220c differ from one another and/or at least some of the CNT layers are part of the same serial electric circuit.
  • Each of the electrodes 230a-230c, 232a-232c comprises an electro-conductive film which is at least partly embedded in the layer stack 200.
  • each of the CNT layers 220a to 220c has been formed partly on top of the electro-conductive film of the corresponding pair of electrodes.
  • each of the electrodes 230a-230c, 232a-232c extends over the width of a side surface of the layer stack 200.
  • the layer stack 200 further comprises a temperature sensor (not shown).
  • the temperature sensor is configured to detect a temperature caused by the electrically heatable layer stack 200 when a current is applied to one or more of the CNT layers 220a to 220c.
  • the temperature sensor is a part of a control system for controlling a heating caused by the layer stack 200.
  • a current applied to the CNT layers can be controlled based on a difference between an intended temperature and a temperature that is detected by the temperature sensor.
  • the layer stack 200 comprises further layers in addition to those shown in figure 2 .
  • the layer stack 200 may comprise more than three functional sub-stacks.
  • the layer stack 200 comprises further substrate layers without a CNT-layer in between.
  • the layer stack 200 is a laminate of substrate layers, for example a laminate of polymer resin, whereas only at some selected heights within the laminate a CNT layer has been inserted.
  • FIG. 3 shows a vehicle assembly group 300 according to an embodiment.
  • the vehicle assembly group 300 comprises an electrically heatable layer stack 330 as presently described.
  • the vehicle assembly group 300 comprises parts of a wing of an aircraft, especially parts of a skin 320, of the aircraft.
  • the electrically heatable layer stack 330 is further arranged in a region of the vehicle assembly group 300 that corresponds to a leading edge 310 of the wing.
  • the vehicle assembly group 300 is an assembly group of a different type of vehicle or comprises parts of a different section of an aircraft, for example, parts of a fuselage or a tail fin of an aircraft.
  • the layer stack 330 is arranged along the leading edge 310 at an outside portion of the skin 320. In that way, the layer stack 330 provides heat directly in those parts where de-icing or anti-icing is required. In comparison to conventional techniques, it is therefore not necessary to heat the entire thickness of the skin 320 from inside the wing 300. The layer stack 330 thus provides efficient heating of the relevant parts of the aircraft.
  • the substrate layers in the layer stack 330 may be formed by the same lamination tape, which is also used to build up the skin 320.
  • the layer stack 330 may be produced during the conventional laminating process when manufacturing the wing skin 320, by additionally including CNT-layers at the required positions between two conventional plies of the polymer laminate. In the described context, heating of up to 100°C may be required, depending on individual conditions and purposes. Accordingly, the number of CNT layers in the stack 330 can be chosen differently in different examples.
  • a typical thickness of a single ply in the laminate of a wing skin 320 lies within the range from 0.15 mm to 3 mm. This corresponds to the thickness of the substrate layers in the layer stack 330, which ranges between 0.05mm and 0.5mm. Moreover, embedding the layer stack 330 into the aircraft skin 320 as described above is also not hindered by the typically decreasing thickness of the skin 320 from the base towards the tip of the wing, for example, from about 10mm at the base to about 2mm at the tip. For, efficient heating by the layer stack 330 can be achieved with stack heights far less than these thicknesses.
  • the laminate forming the skin 320 is typically manufactured starting from an outside of the skin 320, whereas a varying skin thickness is obtained by applying more or less plies to the different regions.
  • the variation in ply numbers thus causes irregularities only at an inside of the skin 320 whereas at the outside, i.e., in the portion where the layer stack 330 is arranged, plies extend regularly over the entire relevant length.
  • the electrically heatable layer stack as presently described thus allows for an efficient implementation in the skin of an aircraft or any other vehicle structure. At the same time, the electrically heatable layer stack does not require space consuming or ponderous installations.
  • the layer stack 330 can be connected to an electric system of the aircraft. Additionally, in some examples, the layer stack 330 can be connected to an electric control system of the aircraft so as to control a current in the CNT layers and a resultant heating temperature at a leading edge 310 of the wing 300. In one example, the layer stack 330 is connected to the electric system such that a current flow is directed in a horizontal direction in all CNT layers, for example, from the base towards the tip of the wing 300.
  • FIG. 4 shows an aircraft 400 according to an embodiment.
  • the aircraft 400 comprises two aircraft assembly groups 402a, 402b, each of which comprises at least parts of a wing of the aircraft 400.
  • the aircraft 400 further comprises an electrically heatable layer stack 430a, 430b arranged in a region that corresponds to a leading edge 410a, 410b of the respective wing of the aircraft 400.
  • FIG. 5 shows a flow diagram of a method 500 for manufacturing an electrically heatable layer stack as presently described.
  • the method 500 comprises providing a first substrate layer, step 510.
  • Providing the first substrate layer may be done, for example, in the context of a lamination process.
  • the method 500 further comprises spraying onto the first substrate layer a dispersion comprising a dispersing agent and carbon nanotubes, CNTs.
  • the carbon nanotubes are contained in the dispersion in a dispersed state, for example, dispersed by means of the dispersing agent, step 520.
  • the method 500 includes removing the dispersing agent from the sprayed-on dispersion, step 530. In that way, a CNT layer is formed on the substrate layer.
  • the method 500 further comprises providing a second substrate layer, step 540, and laminating the second substrate layer onto the CNT layer, step 550.
  • the method 500 further comprises, subsequent to providing the first substrate layer, step 510, laminating the first substrate layer onto a base structure.
  • the base structure may be a previously fabricated sub-stack of a laminate or a previously fabricated sub-stack of an electrically heatable layer stack, as presently described.
  • the base structure can be a part of a mold which is used to give a particular shape to the layer stack, for example, a curved profile according to an aircraft wing's leading edge, as shown in figure 3 .
  • the spraying step 520 is further performed in synchrony with laminating the first substrate layer.
  • FIG. 6 shows an example of a system 600 for manufacturing an electrically heatable layer stack 630 of the above described type.
  • the system 600 comprises a lamination head 610, 612 configured for laminating a substrate 632c onto a base structure 632a, 632b, 634a, 634b to thereby form a substrate layer 632c of a layer stack 630.
  • the laminating head 610, 612 may be implemented in accordance with known techniques.
  • the system 600 further comprises a spraying device 620 configured for spraying a dispersion 622 comprising carbon nanotubes, CNTs, onto the substrate layer 632c.
  • the dispersion 622 is fed to the spraying device 620, for example, from a reservoir.
  • the system 600 further comprises regulation means 624, such as a valve, to regulate the feeding of dispersion to the spraying device 620. In that way, the application of a CNT layer 634c on the laminated substrate layer 632c can be controlled and/or suspended.
  • the system 600 is configured to be moved relative to the base structure 632a, 632b, 634a, 634b during a lamination process.
  • the system 600 allows for a synchronous placing of a substrate layer 632c and creating of a CNT layer 634c on top of the substrate layer 632c. In that way, efficient production of an electrically heatable layer stack as presently described is facilitated. It permits in particular the selective inclusion of heatable portions within a laminate without interrupting a laminating process and without the necessity for additional manufacturing sites.
  • the system 600 provides for efficient means for creating an electrically heatable layer stack embedded in a skin of an aircraft wing, as described in connection with figure 3 .
  • the use of thermoplastic polymer resins in the production of a skin of the aircraft brings about temperatures in the lamination process of about 400°C.
  • Such processing temperatures support a fast evaporation of the dispersing agent in the dispersion 622. Accordingly, the dispersion 622 typically will have dried, and the CNT-layer 634c will have formed, within a repetition interval of the lamination process, that is, before the next ply will be laminated onto the stack 630.

Claims (11)

  1. Elektrisch beheizbarer Schichtstapel (100; 200; 330; 430a, 430b; 630) für eine Flügelhaut (320), umfassend:
    mindestens zwei Substratschichten (110a, 110b; 210a-210d; 632a-632c), und
    mindestens eine Kohlenstoff-Nanoröhren-, CNT-, Schicht (120; 220a-220c; 634a, 634b), die zwischen den Substratschichten (110a, 110b; 210a-210d; 632a-632c) angeordnet ist und die dazu ausgebildet ist, einen elektrischen Strom zu leiten,
    wobei die Substratschichten (110a, 110b; 210a-210d; 632a-632c) und die mindestens eine CNT-Schicht (120; 220a-220c; 634a, 634b) so konfiguriert sind, dass sie eine Erwärmung von mindestens einer der Substratschichten (110a, 110b; 210a-210d; 632a-632c) erzeugen, wenn ein elektrischer Strom an die mindestens eine CNT-Schicht (120; 220a-220c; 634a, 634b) angelegt wird
    dadurch gekennzeichnet, dass die Dicke der Substratschichten (110a, 110b; 210a-210d; 632a-632c) in einem Bereich von 0,05 mm bis 0,5 mm liegt.
  2. Elektrisch beheizbarer Schichtstapel (100; 200; 330; 430a, 430b; 630) nach Anspruch 1, dadurch gekennzeichnet, dass die CNT-Schicht (120; 220a-220c; 634a, 634b) ein Geflecht aus sich gegenseitig kreuzenden Kohlenstoff-Nanoröhren, CNTs, umfasst, das sich in der Ebene der CNT-Schicht (120; 220a-220c; 634a, 634b) erstreckt.
  3. Elektrisch beheizbarer Schichtstapel (100; 200; 330; 430a, 430b; 630) nach Anspruch 1 oder 2, ferner umfassend mindestens eine Elektrode (230a-230c, 232a-232c), die zum Anlegen eines elektrischen Stroms an die CNT-Schicht (120; 220a-220c; 634a, 634b) ausgebildet ist.
  4. Elektrisch beheizbarer Schichtstapel (100; 200; 330; 430a, 430b; 630) nach einem der vorhergehenden Ansprüche, wobei die Substratschichten (110a, 110b; 210a-210d; 632a-632c) aus elektrisch isolierendem Material bestehen.
  5. Elektrisch beheizbarer Schichtstapel (100; 200; 330; 430a, 430b; 630) nach einem der vorhergehenden Ansprüche, wobei die Substratschichten (110a, 110b; 210a-210d; 632a-632c) ein Polymerharz umfassen.
  6. Elektrisch beheizbarer Schichtstapel (100; 200; 330; 430a, 430b; 630) nach Anspruch 5, wobei das Polymerharz ein thermoplastisches Harz ist.
  7. Elektrisch beheizbarer Schichtstapel (200; 330; 430a, 430b; 630) nach einem der vorhergehenden Ansprüche, wobei der Schichtstapel (200; 330; 430a, 430b; 630) eine Vielzahl von Substratschichten (210a-210d; 632a-632c) und eine Vielzahl von CNT-Schichten (220a-220c; 634a, 634b) umfasst, und die Substratschichten (210a-210d; 632a-632c) und die CNT-Schichten (220a-220c; 634a, 634b) abwechselnd in dem Schichtstapel (200; 330; 430a, 430b; 630) angeordnet sind.
  8. Fahrzeugbaugruppe (300; 402a-402b), umfassend einen elektrisch beheizbaren Schichtstapel (100; 200; 330; 430a, 430b; 630) nach einem der Ansprüche 1 bis 7, wobei die Fahrzeugbaugruppe eine Flugzeugbaugruppe (300; 402a-402b) ist und wobei die Fahrzeugbaugruppe (300; 402a-402b) zumindest Teile eines Flügels eines Flugzeugs (400) umfasst, und der elektrisch beheizbare Schichtstapel (100; 200; 330; 430a, 430b; 630) zumindest teilweise in einem Bereich angeordnet ist, der einer Vorderkante (310; 410a-410b) des Flügels (300; 402a-402b) des Flugzeugs (400) entspricht.
  9. Luftfahrzeug (400), umfassend eine Fahrzeugbaugruppe (300; 402a-402b) nach Anspruch 8.
  10. Verfahren (500) zur Herstellung eines elektrisch beheizbaren Schichtstapels (100; 200; 330; 430a, 430b; 630) für eine Flügelhaut, wobei das Verfahren umfasst:
    Bereitstellen (510) einer ersten Substratschicht (632c) mit einer Dicke in einem Bereich von 0,05 mm bis 0,5 mm;
    Sprühen (520) einer Dispersion (622), die ein Dispersionsmittel und Kohlenstoff-Nanoröhren, CNTs, in dispergiertem Zustand umfasst, auf die erste Substratschicht (632c)
    Entfernen (530) des Dispergiermittels aus der aufgesprühten Dispersion (622), so dass eine CNT-Schicht (634c), die so konfiguriert ist, dass sie einen elektrischen Strom leitet, auf der Substratschicht (632c) gebildet wird
    Bereitstellen (540) einer zweiten Substratschicht mit einer Dicke innerhalb eines Bereichs von 0,05 mm bis 0,5 mm, und
    Laminieren (550) der zweiten Substratschicht auf die CNT-Schicht (634c).
  11. Verfahren (500) nach Anspruch 10, ferner umfassend, im Anschluss an das Bereitstellen (510) der ersten Substratschicht (632c), das Laminieren der ersten Substratschicht (632c) auf eine Basisstruktur (632a, 632b, 634a, 634b), wobei das Sprühen (520) der Dispersion (622) zumindest teilweise synchron mit dem Laminieren der ersten Substratschicht (632c) erfolgt.
EP16168951.8A 2016-05-10 2016-05-10 Elektrisch beheizbarer schichtstapel Active EP3244692B1 (de)

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US15/482,178 US11122649B2 (en) 2016-05-10 2017-04-07 Electrically heatable layer stack

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